Resinous composition



PmedOeclaisiz UNITED STATES PATENT OFFlCE "assmoos courosmon Robert a. Burnett, Niskayuna, N. 1., mm: to

General Electric Co :New York No Drawing. Application October M p Serial No. 359,550

Claims.

The prsent invention relates to new and usefnl compositions of matter. *Moreparticularly it is concerned with the production of a novel synthetic resin that is particularly adapted for uses where high resistance to flame is required. This application is a continuation in-part of my company, a corporation of (01. zoo-s1) pending application Serial No. 188,08'7 flled Feb- 3 mary 1, 1938, now Patent No. 2,221,440fissued November 12, 1940, and assignedto the sameas- .signee as the present invention. l V

I have discovered that valuable flame-resisting compositions can be produced by. e'fl'ecting reaction between the components of a mixture comprising essentially (1) an aldehyde and (2) a condensation product of analkaryl ester1con-' taming reactive halogen in the alkyl radical thereof ie. g., tricresyl phosphate containing reactive halogen such as chlorine, bromine, etc., in

, a methyl radical thereof) and anaromatic mono- Ihydroxy compound, specifically a phenol selected from-the class consisting of phenol (CsHsQH) and mono-substituted phenols.

. lllushative examples of other alkaryl esters iihatmay be halogenated in the side chain and the halogenated material used as hereafter more fully described are dicresyl monophenyl phosphate, dicresyl monoxenyl phosphate, dicresyl mononaphthyl phosphate, dicresyl monochlorophenyl phosphate, etc.- Any phosphate or other ester of a slmilarchemical structure may be used. For example, alkaryl carbonates halogenated in the side chain maybe used incarrying the present invention into eifect. 'Mixtures of alkaryl esters may be halogenated and thereafter em-. ployed in forming the flame-resisting resinous compositions of this invention. For practical reasons I prefer to use those esters that are now commercially available, and especially theJphosphates because ofthe improved flame. resistance ofthe end-product: The alkaryl ester may have in the side chain halogens such, ,for'example, as bromine, chlorine, or mixtures thereof, as desiredor as conditions may require. I prefer to mse an .alkaryl ester containing reactive chlorine in the alkyl radical. and, specifically, tricresyl phosphate containing chlorine in a methyl radical thereof; i I

Any suitable method may be employed for halogenating the alkaryl ester; For example, tricresyl phosphate maybe directly chlorinated at to 200 C. in the presence, of ultra-violet light, which serves to acceleratechlorination of the methylgroups. In this way reactive groups i-0113611" and perhaps some -CIIC1=) are formed, and these subsequently can be joined to ,phenol, mono substituted phenols (or to any other aromatic ring containing reactive hydrogen) with thesimultaneous eliminationofHCl.

A more specific illustration oithe chlorination technique is as follows: Chlorinegas is slowly bubbled into tricresyl phosphate heated, with vigorous agitation at about C. for, for example, nine hours in the presence of mild ultraviolet light. In this way a yellow viscous oil containing about20 to 25 per cent by weight of added chlorine is obtained.

The degree of halogenation of the alkaryl phosphate, carbonate, or other alkaryl ester employed, may bevaried. In general, the amount ofhalogen in the side chain groups will range from an average of 1.5to 4, or more, atoms of halogen per molecule of halogenated alkaryl ester. In obtaininghalogenation in the side chain, some halogen also will enter the benzene ring. The ring halogen remains bound during the condensation reaction withthe phenol reactant and,

also, during the reaction of the resulting condensation product withan aldehyde. Since the flame resistance of the final product is improved 1 by the presence of ring halogen in the halogenated alkaryl ester, it is desirable to introduce a substantial amount ot-halogen into the benzene ring during halogenation of the alkaryl ester. It is preferred that the" ratio of ring halogen atoms per molecule to side chain halogen atoms per molecule be ofthe orderof from 1:1 to1z4. Thus, when the amount of halogen in the side chain groups is an average of1.5 to 4, or more atoms of halogen per molecule of halogenated weight 'of chlorine. Because of the high reactivity ofsuch a highly chlorinated. substance'when condensed with phenol or a mono-substituted phenol, it is advantageous to use chlorinated tricresyl phosphate containing less than this amount of totalchlorine in the molecule. Best results have been obtained with chlorinated tricresylphosphate containing about 20 to 25 per centby weight of total chlorine. I

The choice of the phenol reactant used in the preparation of the aldehyde-reactable condensationproduct depends largely upon economic considerations and the particular properties desired in the final product. Thus, in addition to phenol itself, I may use any mono-substituted phenol,

illustrative examples of which are monohalow phenols, e; g., monochloro-phenols, etc., monoalkyl-phenols, e. 'g., the cresols, monoethylphenols, monopropyl-phenols, monobutyl-phenols, monoamyl-phenols, etc., monoaryl-phenols,

"alcohol, butyl alcohol, etc.

e. g., monophenyl-phenols, etc., monoalkarylphenols, e. g., monotolyl-phenols, etc., monoaralkyl-phenols, e. g., monophenvlmethyl-phenols, monophenylethyl-phenols. etc. The substituent group may be in the ortho, meta or para position.

The condensation reaction between the phenol reactant and the halogenated alkaryl ester is carried out asdescribed more fully in my aboveidentified copending application until substantially all the halogen acid has been evolved. As catalysts for the reaction may be used, for example, iron (preferably in sheet form), sulfur, and the halides (e. g., the bromides and chlorides) of iron, aluminum, tin and zinc. Ferric chloride in anhydrous or hydrated form is the preferred catalyst.

To produce the novel resins of this invention I then cause an aldehyde to react with the phenolhalogenated alkaryl ester condensation product. This reaction may be effected under a wide variety of time, temperature and pressure conditions. Ordinarily the reaction is carried out at temperatures at or above the fusion point of the phenol-halogenated ester condensation product.

Reaction may be effected at reduced, atmospheric or superatmospheric pressures. Various aldehydes may be employed, depending upon cost factors and the particular properties desired in the finished product. I prefer to use as the aldehyde reactant formaldehyde or compounds engendering formaldehyde, e. g., paraformaldehyde. For some applications I may use, for instance, acetaldehyde, propionaldehyde, butyraldehyde, acrolein, methacrolein, crotonaldehyde, furfural, benzaldehyde, mixtures thereof, or mixtures of formaldehyde (or compounds engendering formaldehyde) with such aldehydes.

The reaction between the aldehyde and the phenol-halogenated alkaryl ester condensation product may be carried out in the presence or absence of a catalyst. lyst is employed, since thereby the reaction time is decreased. I prefer to use an acidic catalyst, e. g., camphor sulfonic acid, p-toluene sulfonic acid, chloracetlc acid, sulfamic acid, hydrochloric acid, etc.

If desired, the reaction may be carried out in the presence of a solvent, e. g., organic solvents such as methyl alcohol, ethyl alcohol, propyl Such solvents ad- Advantageously a cata' the primary components. Thus, as modifying agents I may use, for instance, amides such as acetamide, stearamide, acryloamides, benzamide,

toluene sulfonamide, adipic diamide, phthalamide, malonyl amides, etc.; urea and substituted ureas; aminotriazines, e. g., melamine, ammeline, ammelide, melem, melam, melon, etch proteins; amines such as ethylene diamine, aniline, phen-. ylene diamine, benzidine, aminophenols, etc. The modifying bodies also may take the form of high molecular weight bodies with or without resinous characteristics, e. g., 'lignin, furfural condensation products, protein-aldehyde condensation products, phenol-aldehyde condensation products, urea-aldehyde condensation products, aminotriazine-aldehyde condensation products (e. g., melamine-formaldehyde condensation products), aniline-aldehyde condensation products, sulfonamide-aldehyde condensation products, modified or unmodified, saturated or unsaturated polyhydric alcohol-polybasic acid condensation products, natural gums and resins, e. g., copal, shellac, rosin, etc. Advantageously the modifying agent is one that is reactable with an aldehyde (e. g., urea, benzidine, aniline, aminotriazines, etc.) or one containing free -COOH groups or other reactive groups whereby the va tageously may be used when the aldehyde reac ant, for instance formaldehyde, is in the form of an aqueous solution. Mixtures of organic solvents also may be employed, for example mixtures of alcohol and solvent naphthas.

The ratio of aldehyde to the phenol-halogenated ester condensation product may be considerably varied. Preferably the amount is chosen so that for each mol of phenol (or mono-substituted phenol) in the phenol-halogenated ester condensation product there is present in the reaction mass more than 1- mol of aldehyde. No particular advantage ordinarily accrues .from using more aldehyde than that required to yield a thermosetting resin. When the curing characteristics of the resin are of secondary consideration, I may use less than 1 mol aldehyde for each mol of phenol (or mono-substituted phenol) in ,the' phenol-halogenated ester condensation product.

The properties of the fundamental resins of this invention may be varied, for example, by introducing various modifying bodies before, during, or after effecting condensation between modifier can chemically tie into the resin molecule and become an integral part thereof. Examples of these last-named modifiers are rosin, shellac and acidic esters, for instance acidic (incompletely esterified) reaction products of a polyhydric alcohol, e. g ycerol, and a polycarboxylic acid or anhydride, e. g., phthalic, maleic,-etc., acid or anhydride.

In order that those skilled in the art better may understand how the present invention may be carried into effect, the following illustrative examples thereof are given:

I Example 1 Step A:

Chlorinated tricresyl phosphate containing about 24% by weight chlorine Phenol 100 Catalyst, specifically ferric chloride (FeClafiHzO) 3.5

, to react with an aldehyde as described below:

The above components were ground together, after which an equal weight of wood flour was thoroughly mixed therewith to form a. molding (moldable) composition. The resulting compound was molded at about C. for about 10 minutes under a pressure of approximately 3000 pounds per square inch. During the molding Parts by weight 8,298,806 x I I 3 Operation the paraformaldehyde reacts with the phenol-chlorinated tricresyl phosphate condensation product. The final product (molded compound) was a hard, cured-article of high mechanical strength and excellent flame resistance. Lower or higher proportions of paraformaldehyde may be used if desired, for examplexfrom 5 to 50 parts paraformaldehyde per 100 parts of the resinous condensation product of step A.

Catalysts other than p-toluene' sulfonic acid may be employed, for instance acidic catalysts such as hereinbefore given by way of example. Any suitable amount of catalyst, may be used. In

general, the higher theamount of catalyst, the faster the resin cures to an insoluble, infusible state.

If desired, the time of curing the resin in the as to yield a thermosetting resin of desired cure point. The fused mass then is cooled, pulverized and mixed with a filler to form a molding composition. Conversion of the resin to an insoluble, infusible state or so-called C-stage" is completed during the molding operation.

Instead of using a phenol-chlorinated tricresyl phosphate condensation product I may use other condensation products of this same general class,

for instance, an o-cresol-chlorinated tricresyl 3 phosphate condensation product prepared, for example, as follows:

Parts by weight Chlorinated tricresyl phosphate containing to by weight chlorine 200 0rtho-cresol 200 lierric' chloride 1 The above components are heated for about three or more hours at 150 to 200 C. until substantially all the hydrochloric acid has been evolved. The resulting product is a hard, red,

thermoplastic resin when cold. It may be reacted with an aldehyde as abovedescribed with particular reference to a phenol-chlorinated tricresyl phosphate condensation product, yielding flame-resisting compositions.

Example 2 Parts by weight Phenol-chlorinated tricresyl phosphate resin described under step A, Example 1 200 Alkyd resin, specifically glyceryl phthalate of about twig acid number 200 Paraformaldehydems 20 Catalyst, specifically p-toluene sulfonic acid- 5 so Essentially the same procedure was followed as described under step B of Example 1, yielding flame-resisting products of the same general,

characteristics as the products of that example. The unfilled resinous condensation product cured to an insoluble, infusible state in about 5 15010 seconds when a small pill of the material was worked on a 170 C. hot plate.

25 article at to 65 properties'of the finished product.

Same procedure was followed as described under step B of Example 1. The cure time at C. (determined as described under Examp1e2) of the unfilled resinous condensation prod- 5 not was less than 5 seconds. The cured article had excellent flame resistance.

Example 4 Parts by weight Phenol-chlorinated tricresyl phosphate resin described under step A, Example 1-.-"-.. 200 r m-r m 100 The above components were caused to react by heating them together at an elevated tem- 15 perature, for example at temperatures of the order of 100 to 160 C. for about 10' to 30 minutes. The reaction preferably is carried out in container providedwith a reflux condenser. A dark brown, soft, thermoplastic resin was ob- 20 tained. The resin was soluble in organic solvents,

e.'g., ethylene dichloride. Solutions of the resin may be used as baking varnishes for insulation of electrical conductors such as copper wires and the like. Upon heating the coated wire or other C. the resin is converted into a black, hard, glossy, insoluble and infusible resinous film- The resin solutions also may be employed for coating or coating and impregnating fibrous materials, for example paper, cotton,

30 linen or other fabrics, glass fibers in filament,

felted, woven or other form, asbestos in yarn, felt, fabric, sheet or. other form, mineral wool, etc. Electrically insulating tapes may be made from the treated sheet materials. 4

Example 5 Step A: Parts by weight Cresol 250 Chlorinated tricresyl phosphate con- 40 taining about 24% by'weight ch10- rine-' 252 Catalyst, specifically ferric chloride (FeCh.6H20) The above components were heated together for about 7 hours at 140 to C., yielding a resin which was brown, fusible and brittle when cold. This resin was pulverized prior to use in carrying out step B.

under step 13 of Example 1. 170 C. (determined as described under Example 2) of the unfilled resinous condensation product was\about 5 to 10 seconds. The cured resin had excellent flame-resisting characteristics.

Dyes, pigmentsand opacifiersmay be incorporated into the compositions of this invention to alter the visual appearance and the optical If needed,

- mold lubricants and plasticizers may be added to facilitate molding of the heat-convertible (heat-curable) molding compositions. Various fillers may be used, for instance, alpha cellulose Example 3 7 in flock form, asbestos including deflbrated as- I p rt by 1 1 1; bestos, sand, mica, wood flour, etc., to obtain a Phenol-chlorinated tricresyl phosphate resin 2 wide variety of molding compositions and molded described under step A, Example 1 200 articles adapted to meet particular conditions.

Benzi m- 50 Other effect agents also may be added as desired Paraformaldehyde 100 75 or as conditions may require.

The cure time atv The resinous compositions of this invention may be used in the production of laminated articles wherein sheets of paper, cloth, asbestos, etc., are treated with the resin, for example in solution state. After removing the excess solvent the resin-impregnated sheets are superimposed and united under heat and pressure to form mechanically strong,- laminated articles of excellent resistance to heat, flame and moisture and of good electrically insulating characteristics.

These new synthetic resins also may be used as impregnants for electrical coils, for bonding together mica flakes to form laminated mica articles as binders. for abrasive particles, in the production of wire enamels and other liquid coating compositions, as modifiers of other natural and synthetic resins, and for numerous other purposes. Thermosetting molding compositions comprising these new resinous materials may be molded into forms suitable for a wide variety of electrically insulating and other applications. For example, they may be molded to form heater connectors such as are used,-for instance, with electric irons, toasters, grills, etc., terminal blocks of watt-hours meters, electrical distributing heads and bodies, etc., or, in general, wherever solid electrical insulation of high heat and flame resistance is desirable.-

What I claim as new and desire to secure by Letters Patent of the United States is:

1. A composition of matter comprising the product of reaction of a mixture comprising (1) an aldehyde and (2) a condensation product of (a) an alkaryl ester selected from the class consisting of alkaryl phosphates and carbonates containing reactive halogen in the alkyl radical thereof and (b) aphenol selected from the class consisting of phenol and monos'ubstituted phenols.

2. A composition as in claim 1 wherein the aldehyde is formaldehyde.

3. A composition as in claim 1 wherein the alkaryl ester is an alkaryl phosphate.

4. A composition of matter comprising the product of reaction of a mixture comprising (1) formaldehyde and (2) a condensation product of -tricresyl phosphate containing reactive halogen in a methyl radical thereof and a phenol selected from the class consisting of phenol and monosubstituted phenols. a 5. A heat-curable resinous composition comprising the product of reaction of a mixture com-' prising (1) paraformaldehyde and (2) a condensation, product of tricresyl .phosphate containing reactive chlorine in a methyl radical thereof and a phenol selected from the class consisting of phenol and mono-substituted phenols. 6. A product comprising the cured resinous composition of claim 5. 4 I 7. The method of producing a resinous composition which comprises efiecting reaction under heat between the components of a mixture comprising essentially (1) an aldehyde and (2) a condensation product of (a) an alkaryl ester selected from the class consisting of alkaryl phosphates and carbonates containing reactive halogen in the alkyl radical thereof and (b) a phenol selected from the class consisting of phenol and mono-substituted phenols.

8. The method of producing a resinous composition which comprises effecting reaction at an elevated temperature between ingredients comprising (1) an aldehyde and (2) a condensation product of an alkaryl phosphate containing reactive halogen in the alkyl radical thereof and a phenol selected from the class consisting of phenol and mono-substituted phenols.

9. The method of producing a flame-resisting resinous composition which comprises eflecting reaction under heat between ingredients comprising (1) formaldehyde and (2) a condensation product of phenol and tricresyl phosphate containing chlorine in both the phenyl and methyl groupings thereof.

10. A flame-resisting composition co prising the resinous reaction product of ingredie'n V comprising (l) paraformaldehyde and (2) s. condensation product of cresol and tricresyl phosphate containing chlorine in both the phenyl and methyl groupings thereof.

ROBERT E. BURNETT. 

